Manually controllable load voltage regulator



MANUALLY CONTROLLABLE LOAD VOLTAGE REGULATOR Filed May 25, 1966 Sheet I of 3 X 16- 3 1 FJ6- 4 Fla-5 INVENTOR Jan. 28, 1969 H. H. MURPHY 3,424,963 I MANUALLY CONTROLLABLE LOA D VOLTAGE REGULATOR Filed May 25, 1966 Sheet 2 of 5 w -w i 7 7 7 Wm v I fla s/r/a/v a; 451/5? /4 FJa- 7 j INVENTOR.

AERM/iW/rf MURPHY ATTORNEY United States Patent 3,424,968 MANUALLY CONTROLLABLE LOAD VOLTAGE REGULATOR Herman H. Murphy, 2107 W. Flower, Fullerton, Calif. 92633 Continuation-impart of application Ser. No. 504,560, Oct. 24, 1965. This application May 23, 1966, Ser. No. 552,154 The portion of the term of the patent subsequent to June 20, 1984, has been disclaimed US. Cl. 318-346 9 Claims Int. Cl. H02p 7/14 ABSTRACT OF THE DISCLOSURE A manually controllable load voltage regulator comprising an electromechanically driven reciprocating armature connected to a supply voltage and spaced between first and second electrical contacts, the first contact being connected to the armature drive and the second contact being connected to a load, the armature being mechanically biased away from the second contact and being operative to periodically and alternately contact the first and second contacts. Manually controllable mechanical means is provided for simultaneously varying the bias of the armature and the spacing between the armature and the second contact to vary the frequency and on time of the signal applied from the voltage supply to the load.

This application is a continuation-in-part of US. Ser. No. 504,560, filed Oct, 24, 1965, now Patent No. 3,327,- 260 by Herman H. Murphy and entitled, Electric Circuit Controller.

This invention relates to electrical devices, and more particularly to a novel electric circuit controller for remotely controlling electrical apparatus including small electrical motors of the type used in model cars, trains, lamps, electric brakes, electric clutches, and the like.

To control miniature, electric motor-driven cars of, for example, the slot racer-type, various switching and power consuming devices have been widely used, none of which truely does a satisfactory job. The ON-OFF type of switch control, for example, is not sufliciently responsive resulting in either the power being applied too long or not long enough. The necessary sensitivity simply cannot be obtained within any economically realistic sense. The other commonly used type of controller utilizes a power consuming rheostat which, in time, as a result of heat dissipation, becomes uncomfortable for the operator and unless properly matched to the source voltage and power ratings, as well as the electrical characteristics of the particular motor driving the racer, the resulting performance of the racer is other than desired. In brief, to achieve proper speed control when using power consuming types of controllers requires that the controller be properly matched to the source and to the load. Such conditions are not always assured, since it is common to operate the slot racer on various tracks, any or all of which may have different power supply characteristics.

These disadvantages are alleviated by the controller according to the invention. By using a vibrating-type mechanism having contact elements which may be manually positioned relative to the vibrating reed element, theoperator can manually control the speed and acceleration rates Patented Jan. 28, 1969 of the car and, when needed or desired, can dynamically brake the miniature car. The operator is in complete control and, as a result of such control, derives more enjoyment and satisfaction than heretofore obtained. The device of this invention provides smooth accurate manual control of load voltage in applications where such control is necesssary or desirable.

Broadly, the device of this invention comprises a manually controllable load voltage regulator which has a means for providing a supply voltage, an electromechanically driven reciprocating supply voltage interrupter, and a manually controllable mechanical means for rapidly and smoothly varying the mechanical time constants of the interrupter. The resultant load voltage varies in correspondence with the varying time constants.

According to one embodiment of the invention, there is I provided an electric circuit controller for operatively controlling a small electrical motor comprising an electrical winding having a core of ferrous material axially disposed and extending through the winding, a frame for supporting the winding and in electrical contact with one end of the winding, a terminal block including a plurality of insulating spacers supportedly attached to the frame, a reed armature mounted on the terminal block and disposed in a plane parallel to the center line of the core and at a predetermined distance therefrom, a first electrical contact mounted on the terminal block and spaced from the reed armature a first predetermined distance, at least one of the insulating spacers being disposed between the first electrical contact and the reed armature, lead means for providing a conductive path between the first electrical contact and the other end of the winding, a second electrical contact mounted on the terminal block and spaced from the reed armature a second predetermined distance, at least one of the insulating spacers being disposed between the second electrical contact and the reed armature, the reed armature being positioned intermediate the first and second electrical contacts, a source of electrical power connected across the reed armature and the frame, means for connecting the small electrical motor across the second electrical contact and the frame, and actuating means including a rod intercoupling the second electrical contact and the reed armature in a predetermined sequence with the first electrical contact and a lever pivotally mounted to the frame and in contact relationship with the rod, the rod including two spaced apart sleeves of nonconductive material, each of the sleeves being disposed in force transmitting relationship with the second electrical contact and with the reed armature at the corresponding outer surfaces thereof to permit the reed armature to engage the first electrical contact as the rod is displaced upon movement of the lever before the second electrical contact engages the reed armature when the rod is fully displaced.

For a more detailed understanding of the invention, reference is made to the drawings in which:

FIG. 1 is a perspective view of one embodiment of an electric circuit controller constructed in accordance with the invention;

FIG. 2 is a partial cross-sectional view of a controller of FIG. 1, showing the operative elements with the actuating mechanism in a normally off position;

FIG. 3 is a partial cross-sectional view of a controller of FIGS. 1 and 2, showing a portion of the actuating mechanism initially displaced a small amount for descriptive purposes;

FIG. 4 is a partial cross-sectional view of a controller of FIGS. 1 and 2, with the actuating mechanism shown in FIG. 3 further displaced to energize the coil winding;

FIG. 5 is a partial cross-sectional view of a controller of FIGS. 1 and 2, with the actuating mechanism of FIGS. 3 and 4 fully displaced for descriptive purposes;

FIG. 6 and FIG. 7 are drafts shown for the purposes of explaining the operative features of the invention;

FIG. 8 is a schematic representation of a wiring diagram of a manually controllable load voltage regulator wherein the electromechanical driver element is provided with a separate source of voltage;

FIG. 9 is a schematic representation of a wiring diagram of a manually controllable load voltage regulator wherein the electromechanical driver element is connected in series across the supply voltage;

FIG. 10 is a schematic representation of a wiring diagram of a manually controllable load voltage regulator wherein a brake circuit is provided;

FIG. 11 is a schematic representation of a portion of a wiring diagram showing a manually controllable mechanical means for varying the mechanical time constants of an electromechanically driven reciprocating supply voltage interrupter in the off position;

FIG. 12 is a schematic representation of the same portion of the wiring diagram shown in FIG. 11 with the brake circuit disengaged by the action of the mechanical means; and

FIG. 13 is a schematic representation of the same portion of the wiring diagram shown in FIG. 11 with the interrupter completely released and in position to actuate the electromechanical driving element.

Referring more particularly to the drawings, in FIG. 1 there is shown an electric circuit controller 10 constructed in accordance with the invention comprising a housing 13 which may be cylindrical in configuration with a removable cap 12 for facilitating fabrication and repair as the case may be.

A trigger or lever 14 for manually operating the controller 10 is pivotally mounted on the outside of the housing 13 by a pivot pin 15. A cable 16, extending from the lower end of the controller 10, includes a power-in clip lead 18, a ground clip lead 19 which may be the stranded shield of the cable 16, and a power-out connection clip lead 20.

As 'best seen in FIGS. 2 through 5, inclusive, leads 18, 19, and 20 are terminated inside the housing 13 at a terminal block 22. Insulating spacers 23 are provided on the terminal block 22 to prevent an electrical short circuit. The block 22 also includes a resilient electrical contact 24, an armature or vibrating reed armature 25, and another resilient electrical contact 26, each of the elements 24, 25, and 26 being suitably separated by the other by one or more spacers 23.

The electrical contacts 24 and 26 each include contact points 2411 and 26a respectively on that side which faces the reed armature 25. In turn, the reed armature 25 includes contact points 25a and 25b for engaging the contact points 24a and 26a respectively.

A threaded fastener 27 is provided to mount the terminal block 22 together with the contacts 24, 25, and 26 and the spacers 23 to a frame 28. Conventional cap screws 29 and 30 may be provided to attach the frame 28 to the housing 13. If desired, bushings 31 may be used to centrally position the frame 28 and the terminal block 22 in the housing 13.

The upper end of the frame 28, which may have an inverted L-shaped configuration, serves as a support for a winding 34 having a core, not shown. One end of the winding 34 is connected to the electrical contact 26 by a conductor 35 and the other end, not shown, of the winding 34 is connected internally to the frame 28.

The reed armature 25 extends upwardly from the terminal block 22, as shown in FIG. 2, towards the winding 34 and is suitably positioned by the insulating spacers 23 so that the center line of the winding 34, hence the core, not shown, parallels the plane defined by the reed armature 25. Stated differently, the center line of the wind ing 34, when extended, does not pass through the reed armature 25, but instead parallels the reed armature 25 at a slight distance therefrom. In the embodiment shown in FIG. 2, for reasons to be described, the reed armature 25 is positioned slightly to the right of the center line of the winding 34.

An opening 42 in the frame 28, reference FIGS. 3 and 4, is provided to receive a threaded stud 43 having a bore 44. A conventional nut may be used to secure the stud 43 in place.

A pin 36 is carried in the bore 44 and engages a rod 38 having an inner insulating sleeve 37 and an outer insulating sleeve 39. The outer ends of the sleeves 37 and 39 are attached to the rod 38, which is longer by a predetermined amount than the combined length of both sleeves, 37 and 39.

Extending through the contacts 24, 25, and 26, and in alignment with the bore 44 are openings, not shown, the latter being of a diameter greater than the sleeve 39 with the other two having a diameter greater than the rod 38 but less than the outside diameter of the sleeves 37 and 39. Thus, as seen in FIG. 2, the sleeve 39 may be moved to the right or left accordingly as the pin 36 is moved without imposing a force of any kind on the electrical contact 26. However, as seen in FIGS. 2, 3 and 4, as the pin 36 is moved progressively more to the right as depicted by the arrows and 51 respectively, both the electrical contact 24 and the reed armature 25 are moved to the right with the spacing therebetween remaining constant and equal to the predetermined distance between the sleeves 37 and 39.

It will be recalled that the rod 38 passes through the opening, not shown, in the electrical contact 24 and the reed armature 25 but the sleeves 37 and 39, which are attached to the rod 38 at its outer end, are too large and instead engage, respectively, with the electrical contact 24 and the reed armature 25. Thus, by either bending the elements 24 and 25 in an appropriate manner or by suitably spacing the contacts 24 and 25 apart with the insulating spacers 23 when assembling the terminal block 22, the proper spring bias can be established which will cause the reed armature 25 to follow the sleeve 39 as the rod 38 is displaced by a fonce applied through the lever 14 to the pin 36. Thus, when a force is applied to the pin 36 to displace the rod 38 the desired maximum amount of travel, as depicted by the arrow 52 in FIG. 5, the reed armature 25 has already engaged the electrical contact 26 as shown in FIG. 5 by the space between the reed armature 25 and the sleeve 39. It is to be noted that the sleeve 37 is always in contact with the contact element 24.

When all forces are removed from the pin 36, the energy stored in the electrical contact 24 is converted to urge the sleeve 37, and hence the rod 38, to the left; eventually, as the sleeve 39 engages the reed armature 25, the reed armature 25 is likewise displaced to the left of its normal free standing position along with the electrical contact 24 until the electrical contact 24 reaches its limit of travel to the left. In this left-most position, the electrical contact 24 makes contact with a stationary electrical contact 40, as shown in FIG. 2, to establish a low resistance path between the power-out clip lead 20 and the ground clip lead 19 through the frame 28 to which the stationary electrical contact 40 is attached by means of the threaded stud 43 and the nut 45.

An opening 48 in axial alignment with the bore 44 is provided in the housing 13, reference FIGS. 2 and 4. A pivot pin support bracket 32, which is attached to the housing 13 and to the frame 28 by the cap screw 30, may extend through the opening 48 to receive the pivot pin 15 for operatively mounting the lever 14 to the controller 10. The pin 36, disposed in the bore 44, has a length suflicient to engage the lever 14 and the rod 38 at the outer end of the sleeve 37 when the lever 14 is positioned in the manner shown in FIG. 2, i.e., the off or inoperative position. Thus, by applying a force to the lever 14 to cause clock-wise rotation about the pivot point 15, the pin 36, and hence the rod 38 and the sleeve 37, and 39, is displaced to the right in FIGS. 2 through 5, inclusive.

The geometry of the lever 14 and the positioning of the bracket 32 may be utilized to limit the travel of the pin 36 to that necessary to cause the electrical contact 24 to engage the reed armature 25 'after the electrical contact 26 has been engaged by the reed armature 25, as shown in FIG. 5 and depicted by the arrow 52. Under such circumstances, the reed armature 25 is constrained from vibrating and the power supplied to the power-in clip lead 18 is applied to the power-out clip lead 20 by way of the reed armature and the electrical contact 24.

In FIG. 6, a waveform 55 graphically describes the periodic voltage available across the frame 28 and the electrical contact 24 meaning the voltage supplied to the power-out clip lead 20 relative to the ground clip lead 19. The waveform 55 is obtained by rotating the lever 14 clock-wise from the position shown in FIG. 2 enough to break contact between the stationary electrical contact and the electrical contact 24 as shown in FIG. 3, and yet just enough to make periodic contact with the vibrating reed armature 25 as shown in FIG. 4. With the contacts 24, 25, and 26 initially disposed in this manner, the winding 34 is energized, power flowing from the source, not shown, through the power-in clip lead, to the reed armature 25 hence to the electrical contact 26 via contact points 2515 and 26a, through the conductor 35 to the winding 34, and returning to the ground clip lead 19 through the frame 28 to the original source. Once energized, the reed armature 25 responds to the magnetic field developed by the winding 34 causing the contact points 25b and 26a to separate and the contact points 25a and 24a to engage and provide a low resistance path for power to flow from the power-in clip lead 18 to the power-out clip lead 20 through the reed armature 25 and the electrical contact 24. The separation of the contact points 25b and 26a interrupts the power flow to the winding 34 which is thereby deenergized and the magnetic field previously established destroyed.

As the reed armature 25 was pulled toward the electrical contact 24 due to the magnetic field, mechanical energy was stored in the resilient reed armature 25, which, as stated above, also has been spring biased in the opposite direction, i.e., towards the electrical contact 26. With the break-down of the magnetic field, the reed armature 25 is returned to again engage the electrical contact 26 via the contact points 25b and 26a to energize the winding 34 and repeat the cycle described.

The period to complete one cycle is shown graphically in FIGS. 6 as t The shaded area of the waveform represents that amount of time during which the reed armature 25 makes contact with the electrical contact 24 which means, the length of time during which the full voltage of the power source, not shown, is applied to the utilization device via the power-out clip lead 20 and the ground clip lead 19.

By rotating the lever 14 still further in a clockwise direction, the electrical contact 24 is moved by the rod 38 and the sleeve 37 still further towards the reed armature 25 and the electrical contact 26. This results in a shorter distance over which the reed armature 25 can periodically travel. This in turn decreases the period slightly from t to t as shown by a waveform 56 in FIG. 6 and results in a slightly longer on or dwell time during which power is applied to the utilization device. A waveform 57 in FIG. 6 illustrates the output characteristics of the controller 10 when the lever 14 is rotated even further in the clockwise direction. Here again, the frequency has increased slightly as shown by a still shorter time period t and a corresponding increase in dwell time represented by the shaded areas under the waveform 57.

A curve 60 representing the electrical output of the controller 10, which may be represented in voltage units, is shown in FIG. 7 as a function of position of the lever 14 and hence the rod 38 and the relative position of the contacts 24, 25, and 26. Assuming that the electrical contact 24 immediately breaks from the stationary electrical contact 40 as the lever 14 is actuated, the voltage out increases substantially linearly with displacement of the lever 14 over a range 58 until that point of which the electrical contact 24 continually engages the reed armature 25. At this point, the output voltage is sharply in creased, as depicted by portion 61, and approaches the voltage level of the source as shown by a flat portion 59 of the curve 60. In other words, over a substantially large range of allowable travel of the lever 14, the electrical output of the controller 10 progressively increases in proportional relation to the lever until at some point the vibratory action ceases and the controller 10 henceforth responds as a closed switch providing circuit continuity between the source of power and the utilization device.

The controller 10 of the invention is particularly suitable for controlling miniature cars of the slot racer type because the full voltage available may be applied for rapid starting, if desired, or the voltage may be varied to maintain a desired speed. In addition, by releasing the lever 14 so that the electrical contact 24 engages the stationary electrical contact 40, a closed circuit can be established across the miniature car motor to electrically brake speed as desired. Since the reed armature 25 and the electrical contact 26 are not engaged in contact relationship when the electrical contact 24 engages the stationary electrical contact 40, such a short circuit is totally isolated from the power supply circuit.

Thus there has been described a specific embodiment of a novel electric circuit controller which affords realistic control of miniature cars, trains, and the like. With such a controller, the operator is in complete command, being able to control not only the speed and acceleration, but also braking action. A minimal amount of power available is consumed by the controller thereby making available to the object controlled a larger amount of power than heretofore. The electrical characteristics also remain substantially unchanged, unlike the power rheostat type of controller the resistance of which may change significantly during prolonged operation. In addition, the vibratory motion and the sound attendant therewith constitute additional inputs to the operator from which to constantly judge the operation and performance of the object controlled.

Referring particularly to FIG. 8 there is shown by schematic representation a circuit for a manually controllable load voltage regulator in which 62 is a means for providing a supply voltage having a first side 64 and a second side 66. An electromechanical driving element 68 is electrically connected to a second source of voltage 70 which is independent of supply voltage means 62. One side of driving element 68 is electrically connected to a first electrical contact 72. Source of voltage 70 is electrically connected to a contact point 74 on armature 76. Contact point 74 is electrically insulated from reciprocating armature 76 by insulating spacer 78. Armature 76 is electrically connected to second side 66. A second electrical contact is spaced apart from first contact 72 and armature 76 is disposed between and normally out of contact with first contact 72 and second contact 80. Armature 72 is mechanically biased, by means not shown, towards first contact 72, and is restrained normally out of contact with first contact 72 by mechanical means, also not shown. Element 68 and armature 76 are so positioned that element 68 drives armature 76 towards second contact 80 when contact point 74 is in electrical contact with first contact 72. Contact point 82 on armature 76 makes electrical contact with second contact 80 when armature 76 has been driven away from first contact 72 by element 68. Second contact 80 is electrically connected to load 84. One

side of load 84 is connected to first side 64. When contact point 82 and second contact '80 are in electrical contact load voltage fiows from supply voltage means 62 to load 84. The tip of armature 76 is provided with a weight or slug 86. Slug 86 may be permanently magnetized if desired to polarize this regulator. In the embodiment illustrated in this FIG. 8, the source of voltage for the driver element is completely independent of the supply voltage.

Referring particularly to FIG. 9, there is shown by schematic representation a circuit similar to that shown in FIG. 8 and described above, except that supply voltage means 62 is connected in series to driving element 68 so that no independent source of voltage is required. Contact point 74 is in electrical contact with armature 76 and driving element 68 is in electrical contact with first side 64.

Referring particularly to FIG. 10, there is shown by schematic representation a circuit similar to that shown in FIG. 8 and FIG. 9, and described above except that a brake circuit is included. Third electrical contact 88 is electrically contacted to load 84 at first side 64. Third contact 88 and second contact 80 are normally in electrical contact with one another. When second contact 80 and third contact 88 are in electrical contact and load 84 is an electrical motor, load 84 is acting as a generator. This results in a braking action being applied to the motor.

Referring particularly to FIG. 11, FIG. 12 and FIG. 13 there is illustrated a schematic representation of a portion of the wiring diagram shown in FIG. with the inclusion of manually controllable mechanical means, indicated generally at 90. Manually releasable means 92 for restraining armature 76 out of electrical contact with first contact 72 is intercoupled for simultaneous movement with manually controllable means 94 for varying the distance between armature 76 and second contact 80. Means for actuating means 96 is adapted to be operated manually. The normal at rest, or unactuated position of means 90 is shown in FIG. 11. The manual operation of actuating means 96 through mechanical linkage with manually releasable means 92 and manually controllabe means 94 first causes second contact 80 and third contact 88 to break electrical contact with one another thus deactivating the brake circuit. This position of means 90 is shown in FIG. 12. As actuating means 96 is further actuated armature 76 is completely released and electrical contact is made between first contact 72 and contact point 74, thus actuating driving element 68. When actuating means 96 is fully actuated, not shown, second contact 80 is in continuous contact with contact point 82 and the supply voltage is the same as the load voltage.

While I have herein shown and described my invention in what I have conceived to be the most practical and preferred embodiments, it is recognized that departures may be made therefrom within the scope of my invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and methods.

I claim:

1. A manually controllable load voltage regulator comprising:

means for providing a supply voltage, said means having a first side and a second side;

an electromechanical driving element electrically connected to said first side;

a first electrical contact, electrically connected in series to said element;

a second electrical contact spaced apart from said first electrical contact;

a reciprocating armature electrically connected to said second side, said armature being disposed between and normally out of contact with said first and second contacts, said armature being mechanically biased toward said first contact, said element being positioned so that it drives said armature toward said second contact when said armature is in electrical contact with said first contact;

an electrical load electrically connected to said first side and to said second contact;

a manually releasable means for restraining said armature out of electrical contact with said first contact; and

manually controllable means for varying the distance between said armature and said second contact.

2. The regulator of claim 1 including:

means for intercoupling said means for restraining and said means for varying so that said armature is released as said armature and said contact are brought closer together.

3. The regulator of claim 1 including:

a third electrical contact electrically connected to said load at said first side, said third contact being normally positioned in contact with said second contact.

4. The regulator of claim 1 wherein said armature is permanently magnetized.

5. An electric circuit controller for operatively controlling an electrical motor comprising:

an electrical winding having a core of ferrous material axially disposed and extending through said winda frame for supporting said winding and in electrical contact with one end of said winding;

a terminal block supportedly attached to said frame;

a reed armature mounted on said terminal block and disposed in operative association with said core;

a first electrical contact mounted on said terminal block and spaced from said reed armature a first predetermined distance;

lead means for providing a conductive path between said first electrical cont-act and the other end of said winding;

a second electrical contact mounted on said terminal block and spaced from said reed armature a second predetermined distance, said reed armature being positioned intermediate said first and second electrical contacts;

a source of electrical power connected across said reed armature and said frame;

means for connecting said electrical motor across said second electrical contact and said frame; and

actuating means including an axially moveable rod intercoupling said second electrical contact and said reed armature in a predetermined sequence with said first electrical contact, said rod including two spaced apart sleeves, each of said sleeve-s being disposed in force transmitting relationship with said second electrical contact and with said reed armature at the corresponding outer surfaces thereof to permit said reed armature to engage said first electrical contact as said rod is displaced before said second electrical contact engages said reed armature when said rod is fully displaced.

6. The electric circuit controller in accordance with claim 5 further characterized in that there is included a third electrical contact supportedly mounted to said frame and in contact relationship with said second electrical contact when said rod is disposed in its normally off position to provide a conductive path between said second electrical contact and said frame, said conductive path being interrupted as said rod is initially displaced before said reed armature engages said first electrical contact to establish circuit continuity between said reed armature and said winding by way of said first electrical contact and said lead means.

7. The electric circuit controller in accordance with claim 6 wherein said second electrical contact is spring biased to urge said second electrical contact outwardly away from said reed armature and towards said third electrical contact, and wherein said reed armature is 9 10 spring biased to urge said reed armature towards said tact while said armature is being electromechanically first electrical contact. driven.

8. A manually controllable load voltage regulator com- A regulator aCCOTding to Claim 8 wherein Said armai i ture is driven by an electromechanical driver element conmeans f providing Supply voltage; 5 nected across said supply volt-age means.

an electrical contact adapted to be electrically connected to an electrical load; References Clted an electromechanically driven reciprocating armature UNITED STATES PATENTS electrically connected to said supply voltage, said 2,437,428 3/1948 H b t l 318 346 X armature being spaced from and operative to period- 10 2,631,265 3/ 1953 Colegrove 318346 'ically contact said electrical contact to connect said 3,304,482 2/1967 Jenks et a1. 307132 X supply voltage to said load, said armature being mechanically biased away from said electrical con- ORIS RADER, Examinerand 15 I. J. BAKER, Assistant Examiner.

manually controllable mechanical means for simultaneously varying the bias of said armature and the U.S.Cl.X.R.

spacing between said armature and said electrical con- 307132 

